Composite wall and method of building the same



E. A. BROOKS 1,837,145

COMPOSITE WALL AND METHOD OF BUILDING THE SAME Dec. 15, 1931.

Filed Oct. 9. 1929 Snnentor Kaye/Z614 .firaolo',

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Patented Dec. 15, 1931 EUGENE A. BROOKS, OF, ATLANTA, GEORGTA.

COMPOSITE WALL AND METHOD OF BUILDING THE SAME Application filed October 9, 1929. Serial No. 398,378.

This invention relates to composite monolithic walls such as those used in furnace or cold storage constructions and a novelmethod of building the same. Among other objects,

; it aims to provide'an improved wallstructure composed of a multiple unit core consisting of improved tiles adapted to be built about or on a supporting frame and having coatings of bonding or cementitious material to form heat insulating or refractory linings applied at high velocity to. one 'or both sides, so that the wholemass bonds itselftogether to form a monolithic,self supporting structure. One of the important features of the meth- 0d is the modeof building a core of tiles about a supporting frame which acts "as a guide to hold the tiles or units plumb and holds the same in position while the bonding surfa'ce or surfaces are being applied under p'res'sure by'means of a fluid pressure gun or its equivalent. f

Other objects and advantages of theinve'nti on will appear in the specification when con sidered in connection with theillustrative $6 embodiment thereof shown in the accompanying drawings, wherein: p y

Fig. 1 is a fragmentary perspective view of a furnace wall embodying the invention;

Fig. 2 is a sectional view taken through a vertical tier of super-imposed bonded tiles; Fig. 3 is a vertical sectional view of the wall showing an opening from which the supporting frame has been removed; and Fig. 4 is a perspective view of one form of tile adapted to be used in the core.

Heretofore, it has been customary to build furnace walls and the like,of masonry, including tiles or units with mortar or cement which necessitated the employment ofbrick masons. and helpers. Monolithic insulating and refractory linings, whenfapplied by the old methods, have not bonded themselves to the core sufiiciently to prevent them from falling off or crumblingfaway. Such walls, when built for boilerfurnaces are very] difficult to repair because the bricks or building elements constituing t-hem are laid so as to break the' joints and cannot easily be removed. This invention aims to overcome all of the foregoing objections by an improved method of constructing walls wherebvthey may be easily andquickly built by unsliilled, cheap labor and also aims to produce an improved monolithic, insulating wall which is eminently adapted for furnaces and the like and. characterized by the lining adhering firmly to the core.

Referring particularly to the drawings, I have there shown the inventive idea applied to; a wall such as is used in boilerfurnaces. However, it is understood that the invention can be advantageously applied to other insulating or refractory walls. 1

In accordancevwith method, a core 10 composed of a series of superimposed tile or block elements 11, herein made of fire clay or other suitablemateriahis first builtfon a suitable base or footing 12. These tiles are here shown as being shaped to receive a supporting member. Herein, they have comple mentary openings 13 at their abutting or ad jacent ends so as to receive a supporting frame 14 conveniently composed of structural steel elements or ordinary pipes. As will be seen in Fig. 1, the core is thus divided into vertical sections or tiers with thetiles in each tier lying one above, another. In furnace walls the usual expansion joints (not shown) maybe provided at suitable intervals. V V

The frame 14 is shown as having a plurality of vertical tubular columns to enable it to be set up and supported on the footing and a relatively long section or length of core portion built around it. The columns may beproperly centered by setting them in central channels or holes in the footings and/or by suitable braces or props. The idea is to make it of sufliciently light weight to be easily handled or set in and lifted out of place. the tiles 11 are set in place about the vertical frame members so that the frame not only acts as a support for the core as it-is being built but. also,holds all of the tilesplumb.

When the core is built to the desired height, the frame is allowed to remain in place until one orboth sides of the core are coatedwith the desired materials, it being understood that the materials used in any caseare suited to the needs of the particular installation The complemental notched ends of or application and commercially available. For example in boiler or furnace walls the core would be made of ordinary refractory material, the inside of the core would be coated or covered with refractory material such as ground the brick and a suitable bonding agent; and the outside would be covered with diatomaceous earthor ground asbestos.

In this example, each of the tiles presents integral longitudinal ribs 15 at the opposite side edges so as to provide bonding or key seats for the coatings. In this example shown in Figs. 1, 2 and 3, an inner lining 16 composed of cheap refractory material such as ordinary fire clay is first appliedby means of high pressure projection or by a fluid pressuregun. Then, a thin layer of super-refractory material, such as silicon carbide mixed with chromic acid or with virgin ball clay, depending upon the reaction desired, is also applied under pressure. This method thus'avoids the excessive expense of applying a single thick layer of super-refractory material.

For the outer coating of a furnace wall, any good heat insulating oementitious material may be used, Herein, a coating 17 about two inches thick of diatomaceous earth CO!11. bined with'a bonding agent is applied under pressure at a high velocity in the same manner as the inside coating. In some walls one coating only of bonding material of the desired composition may be applied.

Now, after the desired coating or coatings are applied, the frame 14 may be'removed by lifting it out ofthe holes in the core. In some cases it may be desirable to leave the frame in place and utilize itefor fluid conduit-s in a manner that will be apparent and/or it may be utilized to support the wall in superposed sections. In case it is left in place, it also acts as a reinforcement for the wall. For example, air, water or other fluid could be circulated through the frame in heat exchanging relation to the wall. In any event, vertical conduit-s are provided because, if the frame is removed, the air conduits are left in the core.

From the foregoing description, it will be seen that my improved wall is made very easily and can be built for less than the building cost of an ordinary wall. The applied coatings are so firmly bonded to the core that they are not easily dislodged. The coatings may be easily renewed by: shooting the coating materials on any eroded place.

Obviously, the invention is capable of various embodiments and is not restricted to the present description. Moreover, the steps of'themethod are capable of a number of variations. Further, it'is not essential that all. of the features of the invention shallbe used conjointly, but they may be employed advanta eously in various combinations and sub-com inations. v

having key surfaces on opposite sides of the core; applying a coating of insulating material. under high velocity to one side of the core; applying a coating of refractory mate rial under high velocity to the other side of the core and temporarily supporting the elements while the coatings are applied.

, 3. That-method of building a composite wall which is characterized by setting up a supporting frame; erecting a center core composed of building units about said frame so that the frame supports the units in their proper positions; applying a coating of bonding material under high velocity to one side of the core; and then removing the frame.

, Flt) 4. That method of building a monolithic wall structure which comprises setting up a supporting frame; erecting a core portion of separateelements about said frame so that the elements engage the frame; and, later coating one surface of the core with refractory materials so as to form a substantially monolithic and self-supporting unitary structure.

5. That method of building a monolithic wall which comprises setting up a removable structural frame; erecting a center core composed of building units about said frame so as to be held in position thereby; applying a coating of refractory material to one side of the core; applying a coating of insulating material to the opposite side of the core; and removing the frame after the coatings are set and the wall becomes self-supporting.

6. That method of building a composite,

monolithic wall which is characterized by setting up a frame having substantially vertical columns; erecting a core about said frame; applying bonding materials under pressure at high velocity to the opposite sides of the core; and then removing the frame so as to leave fluid conduits in the'wall.

7. That method of building a refractory furnace wall which comprises first erecting a core of separate heat resisting tiles arranged one above another in vertical tiers or sections; temporarilysupporting said tiles in place; applying a cementitious coating of refractory materials at high velocity to the inside of said core; and applying bonding mortar to the outside of the core so as to produce a substantially unitary, bonded, monolithic structure.

8. A monolithic wall comprising a core portion composed of separate tiles loosely laid one upon another in adjacent vertical tiers and aving complemental notches in their ends; said tiles having key-forming projections on opposite sides of the core; and

bonding coatings of cementitious material applied to the opposite sides of the core to make a monolithic, self-supporting structure.

9. A monolithic furnace wall comprising a core portion composed of separate tiles loosely laid one upon another in adjacent vertical tiers and having complemental notches in their ends; said tiles having ke -forming projections on opposite sides of t e core; a coating of bonding mortar applied to the outside of the core; and a coatin resisting material applied to the inside of the core. a

In testimony, that I claim the foregoing as my own, I have hereto aflixed my signature.

EUGENE A. BROOKS. 

